Lopi Freedom Insert Installed, Need Custom Surround Panels

It looks like Lopi uses sheet steel for their surround. I would use the same. I would ship-lap the surround extensions behind the OE surround and paint the extensions with stove bright of the same color as the insert. The specs for the unit say it is made of 5/16 to 3/16 steel. 3/16 or even 1/8th thickness should be fine. You should be able to have the extensions cut by a local steel fab shop. I would explain to the shop what you are doing so they understand this is going into your living space and needs to be able to be nicely finished. You should supply them a drawing of what you want the piece/pieces to look like with dimensions.

I would connect the extensions with small round head carriage bolts. Make sure you de-grease the steel before painting.

Here is mine. stone put on top of everything.

submitted to the insurance company for backing... lets see how that goes...
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the instalation company did the whole thing. the metal was just a big piece of metal as i remember, certainly thicker than "sheet metal" i would guess 3/16". pretty serious stuff, they werent messing around.

How big are your panels now? Lopi makes 8",10",and 12" panels. Ordering the correct panels would be the best. If they still won't reach, you can have some 18 gauge angles made. Paint them black and attach them to the opening on the fireplace. Have the angles made large enough to fit behind the factory panels and then just slid the unit back against the panels.